EFFECTS OF CUTTER GEOMETRICAL FEATURES ON MACHINING POLYETHERETHERKETONES (PEEK) ENGINEERING PLASTIC
|
|
- Hester Richardson
- 7 years ago
- Views:
Transcription
1 Journal of Mechanical Engineering and Sciences (JMES) ISSN (Print): ; e-issn: ; Volume 6, pp , June 2014 Universiti Malaysia Pahang, Malaysia DOI: EFFECTS OF CUTTER GEOMETRICAL FEATURES ON MACHINING POLYETHERETHERKETONES (PEEK) ENGINEERING PLASTIC R. Izamshah 1*, N. Husna 2, M. Hadzley 1, M. Amran 2, M. Shahir 2 and M. Amri 2 1 Center of Excellence for Advanced Manufacturing, Universiti Teknikal Malaysia Melaka, Hang Tuah Jaya, Melaka, Malaysia. * izamshah@utem.edu.my Phone: ; Fax: Department of Manufacturing Process, Faculty of Manufacturing Engineering, Universiti Teknikal Malaysia Melaka, Hang Tuah Jaya, Melaka, Malaysia. ABSTRACT When polyetheretherketone is used in structural applications it generally undergoes additional machining operations in order to form components. Machining PEEK can be a challenging task for manufacturers, however, especially when using a conventional cutting tool. This paper deals with the influence of a cutter s geometrical features when machining polyetheretherketones engineering plastic on their machining performances. Three categories of end mills were designed and fabricated with varying rake angles, clearance angles and helix angles to investigate effects on machining surface roughness and burr formation. From the investigations conducted, it is evident that end mill geometrical features (rake angle, clearance angle and helix angle) have significant effects on machining surface roughness and burr formation. Increasing the rake angle and helix angle value will improved the machining surface roughness, however, in the case of varying clearance angles, there are no significant results for the surface roughness produced. It could be observed, however, that a 12 clearance angle produced better surface roughness compared to other angles. The findings from the deliberately conducted experiments can be used for the development of high performance cutting tools, especially for machining polyetheretherketones engineering plastic material. Keywords: Machining; polyetheretherketones; end mill angles; surface roughness. INTRODUCTION Polyetheretherketones (PEEK) are one of the thermoplastic polymers that has excellent stability in high temperatures, resistance to chemicals and radiation, good strength and is biocompatible (Denault & Dumouchel, 1998). It is a semi-crystalline polymer which consists of polyaromatic ketones that contribute to toughness, stiffness and the flexibility of its structure. Due to its good chemical and mechanical structure, PEEK thermoplastic has been widely used in the aerospace, electronics and medical industries. PEEK was commercialized in implant components for orthopedic and trauma applications because of its biodegradable characteristics and non-allergic reactions compared to metal implants (Kurtz & Devine, 2007). Figure 1 shows an example of PEEK application for a medical implant. Processing some plastics can be easily scaled up to meet the increasing demand for product parts. Incorporating plastic technologies 863
2 Effects of cutter geometrical features on machining Polyetheretherketones (Peek) engineering plastic (for example, injection molding) means that the economics of production are viable on a larger scale, while complex shapes can be formed as required to aid device fabrication. However, it is often not economically viable to manufacture an injection molding tool for prototype designs or short production runs. Under such circumstances, it is common to employ a machining process on PEEK polymer materials to form the components. Traditional manufacturing methods associated with metallic implants are generally not satisfactory for polymeric materials. Polymers are relatively soft when compared to implant alloys and this can create manufacturing problems related to machining, deburring, and cleaning operations. Figure 1. PEEK application for medical implant (Xilloc, 2013) Very few research works dealing with machining PEEK have been reported. In most cases, research only concentrated on the effect of cutting parameters on machining performances. In addition, machining was done using a lathe machine, in which the cutting tool geometry is not complex compared to end milling. Davim and Mata (2006) investigated the effect of PCD (Polycrystalline Diamond) tool inserts when turning PEEK material with different cutting speeds (150 m/min, 250 m/min and 377 m/min) and feed rates (0.05 mm/rev, 0.1 mm/rev and 0.2 mm/rev). They found that increasing the cutting speed contributed to high cutting pressure and minimized the surface roughness value, and increasing the feed rate, led to low cutting pressure and increased the surface roughness value. Mata, Gaitonde, Karnik, and Davim (2009) also investigated the interaction effects of cutting speed and feed rate towards the machinability of reinforced and unreinforced PEEK with PCD cutter insert. They found that a high feed rate will increase the machining power and decrease the cutting pressure at specific cutting speeds. The research also showed that reinforced PEEK has poor machinability compared to unreinforced PEEK. Although the reinforced elements can improve strength and stiffness properties, the machining cost is high, as reinforced PEEK is extremely abrasive. In a later work, Mata et al. (2009) studied the physical cutting model of reinforced PEEK CF30 and unreinforced PEEK chip thickness, chip deformation, shear stress and normal stress after machining. They demonstrated that PEEK CF30 has high normal and friction stress compared to unreinforced PEEK because of the existence of fiber. Meanwhile, chip deformation of PEEK CF30 was smaller compared to unreinforced PEEK because of the fragility of the carbon fiber. It can be seen in the literature that most of the research in machining PEEK engineering plastic only focuses on few areas such as machining parameters, cutting 864
3 Izamshah et al. / Journal of Mechanical Engineering and Sciences 6(2014) tool material and fiber reinforced types. Little attention is given to the effect of cutter geometry on machining performance due to its complexity. Chatelain and Zaghbini (2012) observed that cutter geometrical features can influence cutting performances, especially in surface finish, dimensional tolerances and cutting forces. Thus, investigation of the effect of cutter geometrical features is important for effectively machining polyetheretherketones (PEEK) engineering plastic material. END MILL GEOMETRICAL FEATURES The geometrical features of end mill consists of a core diameter, inscribed circle diameter, rake angle, clearance angle and helix angle. Each of the geometric features has their specific function and will significantly affect the machining performance. Figures 2 and 3 show the end mill geometrical terminology and the cutting angles respectively. Rake angle can have a significant effect on the cutting forces, stress distribution, chip deformation, cutting edge stiffness and rigidity of the tool (Izamshah, Yuhazri, Hadzley, Ali, & Subramonian, 2013). An end mill with a positive rake angle will improve machinability, thereby producing a lesser cutting force and cutting temperature. Baldoukas, Soukatzidis, & Demosthenous (2008) investigated the decrease in cutting force with increasing rake angle. Meanwhile, (Shirpurkar, Bobde, Patil, & Kale, 2012) found that rake angle influenced the cutting forces, power consumption and surface finish. The cutting forces and power were minimized when using a tool with high rake angle, and produced a good surface finish. However, too large a rake angle reduces the edge strength of the tool due to friction and stress distribution. Thus, a proper selection of rake angle value is vital and needs to be considered for specific application. Figure 2. End mill geometrical terminology. Relief angle can also affect the performance of a cutting tool. Relief angle or clearance angle is the angle between the cut surface and the clearance flank on the cutter. To obtain a good tool life a high value of clearance angle is preferred. However higher values of clearance angle tend to weaken the cutting edge, which becomes overheated because of poor heat transfer from the cutting edge. In the case of end mills, smaller clearance angles reduce the chip space for the same number of teeth. In such cases, primary and secondary clearances are provided. The value of clearance angles also depends on the diameter of the end mill. Smaller end mills have larger relief angles. 865
4 Effects of cutter geometrical features on machining Polyetheretherketones (Peek) engineering plastic As an example, machining of CFRP composite requires a high relief angle to control the bouncing of the fiber and prevent the tool from rubbing with the workpieces. A high relief angle can also enhance the cutting edge quality of the laminate polymer. Tunc and Budak (2012) experimentally investigated the influence of clearance angle on process damping and stability. They demonstrated that process damping increased regularly with increased clearance angle value. Figure 3. End mill cutting angles. Helix angle is the angle formed by a line tangent to the helix and a plane through the axis of the cutter or the cutting edge angle, which a helical cutting edge makes with a plane containing the axis of a cylindrical cutter. A large helix angle can reduce tool deflection by transferring stress vertically which allows the end mill to produce vertical chip ejection. Yang, Chang, Lee, Kim, & Ko (2003) investigated the shear forces and friction of different end mill helix angles of 30º, 40º and 50º. They demonstrated that shear stress and friction energy increased as the helix angle increased. In addition, greater shearing action results in increased speeds and feeds and faster stock removal. EXPERIMENTAL DESIGN AND SETUP Using a CNC tool cutter grinder Michael Deckel S20 Turbo machine, design parameters and proper wheel geometries were determined to produce the end mill. A two flutes carbide flat end mill with a diameter of 10mm and total length of 70mm was fabricated to analyze the effect of variable rake angle, helix angle and clearance angle on machining polyetheretherketones (PEEK) engineering plastic material, as depicted in Table 1. Table 2 lists the rake angles, helix angles and clearance angles designed for the experiment. In this experiment, three categories of end mills were designed to investigate the effects on machining surface roughness and burr formation. The first end mill category was designed to maintain varying rake angles of 5 o, 10 o and 15 o with a constant clearance angle of 10 o and helix angle of 30 o (Figure 4 (a)). The second category was designed to maintain varying clearance angles of 6 o, 8 o, 12 o and 14 o with a constant rake angle of 14 o and helix angles of 30 o (Figure 4 (b)). The following category was designed to maintain varying helix angles of 20 o, 25 o, 30 o, 35 o and 45 o with a constant rake angle of 8 o and clearance angles of 6 o as depicted in Figure 5. Other 866
5 Izamshah et al. / Journal of Mechanical Engineering and Sciences 6(2014) design factors were held constant. Each of the fabricated end mills were then measured using a tool microscope for accuracy. Table1. End mill specification. Material Diameter Overall length Flute length Bottom No. of flute Micro grain carbide rod HRC mm 70 mm 40 mm Flat 2 Table 2. Design parameter for end mill. Tool Rake angle (Degree) Clearance angle (Degree) Helix angle (Degree) Table 3. Workpiece and machining parameters used in the experiment. Workpiece Polyetheretherketones TECAPEEK Tensile strength at yield 95Mpa Rockwell hardness M99 Density 1.32g/cm^3 Melting temperature 343ºC Glass transition temperature 143ºC Coefficient of thermal expansion 50 x 10E-6 mk Machining parameter Cutting speed Depth of cut Feed Coolant 6000rpm 5mm 100mm/min Dry cut 867
6 Effects of cutter geometrical features on machining Polyetheretherketones (Peek) engineering plastic The workpiece used in the experiment was a polyetheretherketone (PEEK) thermoplastic polymer sheet manufactured by TECAPEEK. Slot milling cutting tests were conducted using a 5-axis Deckel Maho milling machine to investigate the machining surface roughness with respect to the changes in rake angle, helix angle and clearance angle. After the machining process, the surface roughness value and burr formation were measured using a Mitutoyo SJ-301 portable surface roughness tester and optical microscope respectively. Table 3 shows the workpiece and machining parameters used for the slot milling experiment. Figure 4. End mill fabrication of various rake angles and clearance angles. EXPERIMENTAL RESULTS Table 4 shows the machining surface roughness on PEEK material of varying rake angles, clearance angles and helix angles. The result show that a combination of 15 rake angle, 10 o clearance angle and 30 o helix angle result in a minimum surface roughness of 0.26µm, and a combination of 8 rake angle, 6 o clearance angle and 25 o helix angle result in a maximum surface roughness of 1.21µm. It can be seen that increasing the rake angle value will improve the surface roughness. This is due to the increase in tool sharpness, which helps the chip eject easily. In addition, the sharp tool produces optimum shear stress on soft polymer plastics and allows for faster feed rates to cut the PEEK polymer. There were no significant results for varying clearance angle, on the surface roughness produced, however, it could be observed that a 12 relief angle 868
7 Izamshah et al. / Journal of Mechanical Engineering and Sciences 6(2014) produced better surface roughness compared to other angles. One of the possible reasons is the ability of the end mill to maintain its stability and thus reduce the friction between the tool and the workpiece surface. Figure 5. Various helix angles (25 o, 30 o, 35 o, 40 o, 45 o ) with constant clearance angles (6 o ) and rake angle (8 o ). In another case, there was a significant improvement in the surface roughness values by increasing the helix angle, which agreed with results of other studies. A high helix angle can effectively help the chip extraction away from the cutting zone whilst reducing the stuck-chip disruption. Machining surface roughness can thus be improved by increasing the helix angle value. The findings agree with previous studies by Moetakef Imani (2009), and Chatelain and Zaghbini (2012) which demonstrated that a helical cutter with a large helix angle produced a smooth surface and low cutting force distribution compared to a small helix angle. Tool Rake angle Table 4. Experimental measured values of surface roughness. Clearance angle Helix angle Surface roughness (µm) Run 1 Run 2 Run 3 Average
8 Effects of cutter geometrical features on machining Polyetheretherketones (Peek) engineering plastic The burr formation characteristic at the machined edge surfaces changes with the varying rake angle values. Large rake angles produced thin and continuous chip morphology at the side machining surface which shows that the high shear stress occurred at the PEEK polymer as shown in Figure 6. The high shear stress increased the strain rate of the PEEK polymer due to the behavior of thermoplastic properties, which exhibited high elastic strain proportional with the stress increment (Fried, 2003; Sheikh-Ahmad, 2009). Figure 6. Chip morphology and burr formation with large rake angle. For varying the clearance angles, there was no significant change in the characteristic. All burr formation had the same characteristic which was a long and continuous chip, as shown in Figure 7. Although there is no significant effect of varying clearance angles on burr formation, the proper selection of clearance angle in terms of stability and machining vibration is necessary (Tunç & Budak, 2012). Figure 7. Long and continuous chip morphology and burr formation with varying clearance angles. The burr formation characteristic at the machined edge surfaces changes with the varying helix angle values. It is found that a large helix angle will result in thick and continuous chips compared to a low helix angle, as a result of high shearing force. Figure 8 shows chip formation for a large helix angle cutting tool which indicates the 870
9 Izamshah et al. / Journal of Mechanical Engineering and Sciences 6(2014) polymeric softening as a result of localized heat on cutting zone (Sheikh-Ahmad, 2009; Yang et al., 2003). Figure 8. Thick and continuous chip morphology and burr formation with large helix angle. CONCLUSIONS From the investigations conducted, it is evident that end mill geometrical features (rake angle, clearance angle and helix angle) have significant effects on machining surface roughness and burr formation. Increasing the rake angle and helix angle value will improve the machining surface roughness, however, in the case of varying clearance angle, there are no significant results for the surface roughness produced. It could be observed, however, that a 12 relief angle produced better surface roughness compared to other angles. The findings from the deliberately conducted experiments can be used for the development of high performance cutting tools, especially for machining polyetheretherketones (PEEK) engineering plastic material. ACKNOWLEDGEMENTS The authors gratefully acknowledge the Malaysian Ministry of Higher Education for supporting the work under Fundamental Research Grant Scheme No. FRGS(RACE)/2012/FKP/TK01/02/1/F REFERENCES Baldoukas, Α., Soukatzidis, F., & Demosthenous, G. (2008). Experimental investigation of the effect of cutting depth, tool rake angle and workpiece material type on the main cutting force during a turning process. Paper presented at the Proceedings of the 3rd International Conference on Manufacturing Engineering (ICMEN), Greece. Chatelain, J., & Zaghbani, I. (2012). Effect of tool geometry special features on cutting forces of multilayered cfrp laminates. Journal of Composite Materials, Davim, P., & Mata, F. (2006). Chemical vapour deposition (cvd) diamond coated tools performance in machining of peek composites.. Materials & Design, 29 (8),
10 Effects of cutter geometrical features on machining Polyetheretherketones (Peek) engineering plastic Denault, J., & Dumouchel, M. (1998). Consolidation process of peek/carbon composite for aerospace applications. Advanced Performance Materials, 5(1-2), Fried, J. (2003). Polymer science and technology (2nd ed.). USA: Prentice Hall. Izamshah, R., Yuhazri, M. Y., Hadzley, M., Ali, M. A., & Subramonian, S. (2013). Effects of end mill helix angle on accuracy for machining thin-rib aerospace component. Applied Mechanics and Materials, 315, Kurtz, S. M., & Devine, J. N. (2007). Peek biomaterials in trauma, orthopedic, and spinal implants. Biomaterials, 28(32), Mata, F., Gaitonde, V., Karnik, S., & Davim, J. P. (2009). Influence of cutting conditions on machinability aspects of peek, peek cf 30 and peek gf 30 composites using pcd tools. Journal of Materials Processing Technology, 209(4), Moetakef Imani, B. (2009). Effects of helix angle variations on stability of low immersion milling. IUST International Journal of Engineering Science, 19(5), Sheikh-Ahmad, J. Y. (2009). Machining of polymer composites. New York: Springer. Shirpurkar, P., Bobde, S., Patil, V., & Kale, B. (2012). Optimization of turning process parameters by using tool inserts-a review. International Journal of Engineering and Innovative Technology, 2(6), Tunç, L. T., & Budak, E. (2012). Effect of cutting conditions and tool geometry on process damping in machining. International Journal of Machine Tools and Manufacture, 57, Xilloc. (2013). Patient specific implants. from products_services/. Yang, S., Chang, S., Lee, Y., Kim, H., & Ko, T. (2003). Analysis of shear and friction behaviors in end milling process. Cailiao Kexue Yu Jishu (Journal of Materials Science & Technology) (China), 19,
GEOMETRY OF SINGLE POINT TURNING TOOLS
GEOMETRY OF SINGLE POINT TURNING TOOLS LEARNING OBJECTIVES Introduction to Features of single point cutting tool. Concept of rake and clearance angle and its importance System of description of Tool geometry
More informationHigh speed machining and conventional die and mould machining
High speed machining and conventional die and mould machining Reprint from HSM - High Speed Machining There are a lot of questions about HSM today and many different, more or less complicated, definitions
More informationChapter 2 Fractal Analysis in CNC End Milling
Chapter 2 Fractal Analysis in CNC End Milling Abstract This chapter deals with the fractal dimension modeling in CNC end milling operation. Milling operations are carried out for three different materials
More informationSolid shape molding is not desired in injection molding due to following reasons.
PLASTICS PART DESIGN and MOULDABILITY Injection molding is popular manufacturing method because of its high-speed production capability. Performance of plastics part is limited by its properties which
More informationAdvance in Monitoring and Process Control of Surface Roughness Somkiat Tangjitsitcharoen and Siripong Damrongthaveesak
Advance in Monitoring and Process Control of Surface Roughness Somkiat Tangjitsitcharoen and Siripong Damrongthaveesak Abstract This paper presents an advance in monitoring and process control of surface
More informationMilling. COPYRIGHT 2008, Seco Tools AB 1/111
Milling 1/111 2/111 Milling A simple choice! Experts required? No Just follow some basic rules. 3/111 Face milling 4/111 Square shoulder milling 5/111 Disc milling 6/111 Copy milling 7/111 Plunge milling
More informationJournal of Engineering and Natural Sciences Mühendislik ve Fen Bilimleri Dergisi
Journal of Engineering and Natural Sciences Mühendislik ve Fen Bilimleri Dergisi Araştırma Makalesi / Research Article TURNING OF AISI 304 AUSTENITIC STAINLESS STEEL Sigma 2006/2 Cebeli ÖZEK, Ahmet HASÇALIK,
More informationThink precision, Think HSS REAMING
Think precision, Think HSS REAMING SUMMARY REAMING TOOLS 2 Zoom on a reamer 3 Which HSS for maximum efficiency? 4 Coatings for the best performance 5 Vocabulary 6 Choose the right design 7 Types of bevel
More informationCutting Tool Materials
Training Objectives After watching the video and reviewing this printed material, the viewer will gain knowledge and understanding of cutting tool metallurgy and specific tool applications for various
More informationCUTTING TOOL TECHNOLOGY. 1. Tool life 2. Tool Materials 3. Tool Geometry 4. Cutting fluids
CUTTING TOOL TECHNOLOGY 1. Tool life 2. Tool Materials 3. Tool Geometry 4. Cutting fluids 1 Introduction Machining is accomplished by cutting tools. Cutting tools undergo high force and temperature and
More informationThree Key Elements of a Cutting Tool
End Mill Training Three Key Elements of a Cutting Tool Geometry Cutting Tool 3 Elements Needed in a Good Cutting Tool Well Balanced For Best Performance Only Good as the Weakest Link End Mill Terms A -
More information8.1 HPC for improved efficiency on standard machine tools by using new fluid-driven spindles
8.1 HPC for improved efficiency on standard machine tools by using new fluid-driven spindles A. Schubert 1, O. Harpaz 2, B. Books 2, U. Eckert 1, R. Wertheim 1 1 Fraunhofer IWU, Reichenhainer Str. 88,
More information4 Thermomechanical Analysis (TMA)
172 4 Thermomechanical Analysis 4 Thermomechanical Analysis (TMA) 4.1 Principles of TMA 4.1.1 Introduction A dilatometer is used to determine the linear thermal expansion of a solid as a function of temperature.
More informationINTERTECH 2006. EDM Technology To cut PCD Materials. Presented by. Eric Ostini Product Manager +GF+ Agie Charmilles Group
INTERTECH 2006 EDM Technology To cut PCD Materials Presented by Eric Ostini Product Manager Agie Charmilles Group +GF+ Outline Goal of the presentation What is PCD PCD applications that commonly used Wire
More informationIntroduction to JIGS AND FIXTURES
Introduction to JIGS AND FIXTURES Introduction The successful running of any mass production depends upon the interchangeability to facilitate easy assembly and reduction of unit cost. Mass production
More informationModule 3 Machinability. Version 2 ME, IIT Kharagpur
Module 3 Machinability Lesson 1 Cutting Tool Materials of common use Instructional Objectives At the end of this lesson, the students will be able to (i) Identify the needs and cite the chronological development
More informationCOATED CARBIDE. TiN. Al 2 O 3
COATED CARBIDE GENERAL INFORMATION CVD = Chemical Vapour Deposition coated grades GC2015, GC2025, GC2135, GC235, GC3005, GC3015, GC3020, GC3025, GC3115, GC4015, GC4025, GC4035, S05F, and CD1810. PVD =
More information6.6 GEAR MANUFACTURING. Introduction. Gear forming
Valery Marinov, Manufacturing Technology Gear Manufacturing 123 6.6 GEAR MANUFACTURING Introduction Because of their capability for transmitting motion and power, gears are among the most important of
More informationNumerical Analysis of Independent Wire Strand Core (IWSC) Wire Rope
Numerical Analysis of Independent Wire Strand Core (IWSC) Wire Rope Rakesh Sidharthan 1 Gnanavel B K 2 Assistant professor Mechanical, Department Professor, Mechanical Department, Gojan engineering college,
More informationChapter 6 Machining Center Carbide Insert Fundamentals
This sample chapter is for review purposes only. Copyright The Goodheart-Willcox Co., Inc. All rights reserved. N10G20G99G40 N20G96S800M3 N30G50S4000 N40T0100M8 N50G00X3.35Z1.25T0101 N60G01X3.25F.002 N70G04X0.5
More informationA Guide to Thermoform Processing of Polypropylene. Introduction
A Guide to Thermoform Processing of Polypropylene Introduction Thermoforming is the process of heating plastic sheet to a pliable state and forming it into shape. Thermoforming offers processing advantages
More informationAISI O1 Cold work tool steel
T OOL STEEL FACTS AISI O1 Cold work tool steel Great Tooling Starts Here! This information is based on our present state of knowledge and is intended to provide general notes on our products and their
More informationUnderstanding Plastics Engineering Calculations
Natti S. Rao Nick R. Schott Understanding Plastics Engineering Calculations Hands-on Examples and Case Studies Sample Pages from Chapters 4 and 6 ISBNs 978--56990-509-8-56990-509-6 HANSER Hanser Publishers,
More informationManufacturing Tooling Cutting Tool Design. Elements of Machining. Chip Formation. Nageswara Rao Posinasetti
Manufacturing Tooling Cutting Tool Design Nageswara Rao Posinasetti Elements of Machining Cutting tool Tool holding Guiding device Work piece Machine tool January 29, 2008 Nageswara Rao Posinasetti 2 Chip
More informationMechanics and Dynamics of 5-axis Ball-end Milling Operations
Mechanics and Dynamics of 5-axis Ball-end Milling Operations Erdem OZTURK, PhD.Candidate L.Taner TUNC, PhD. Candidate Assoc.Prof. Erhan BUDAK Manufacturing Research Laboratory, SABANCI UNIVERSITY, ISTANBUL
More informationMachining of glass fiber reinforced polyamide
express Polymer Letters Vol.1, No.12 (2007) 810 816 Available online at www.expresspolymlett.com DOI: 10.3144/expresspolymlett.2007.112 Machining of glass fiber reinforced polyamide F. Quadrini, E. A.
More informationEXPERIMENTAL AND NUMERICAL ANALYSIS OF THE COLLAR PRODUCTION ON THE PIERCED FLAT SHEET METAL USING LASER FORMING PROCESS
JOURNAL OF CURRENT RESEARCH IN SCIENCE (ISSN 2322-5009) CODEN (USA): JCRSDJ 2014, Vol. 2, No. 2, pp:277-284 Available at www.jcrs010.com ORIGINAL ARTICLE EXPERIMENTAL AND NUMERICAL ANALYSIS OF THE COLLAR
More informationPhenomenological aspects of a modified fragmentation of the ground material
Phenomenological aspects of a modified fragmentation of the ground material Lucjan Dabrowski, Mieczyslaw Marciniak Warsaw University of Technology, Warsaw, Poland Summary: The main point of this paper
More informationMilling & Machining Centers
Training Objective After watching the program and reviewing this printed material, the viewer will gain knowledge and understanding of basic milling theories and procedures. In addition, the viewer will
More informationTHE INFLUENCE OF STEEL GRADE AND STEEL HARDNESS ON TOOL LIFE WHEN MILLING IN HARDENED TOOL STEEL
THE INFLUENCE OF STEEL GRADE AND STEEL HARDNESS ON TOOL LIFE WHEN MILLING IN HARDENED TOOL STEEL S. Gunnarsson, B. Högman and L. G. Nordh Uddeholm Tooling AB Research and Development 683 85 Hagfors Sweden
More informationVerification Experiment on Cooling and Deformation Effects of Automatically Designed Cooling Channels for Block Laminated Molds
International Journal of Engineering and Advanced Technology (IJEAT ISSN: 2249 8958 Volume-4 Issue-5 June 2015 Verification Experiment on Cooling and Deformation Effects of Automatically Designed Cooling
More informationCutting force, Fc (N) ' 270. 100 110 120 130 Cutting speed (m/min)
159 Rake face Adhesion Rake face Nose wear Tool life = 50.2 min Nose wear Tool life = 30.9 min Figure 4.19 - Nose wear at the cutting edge of T4 coated carbide insert after machining Ti- 6Al-4V alloy with
More informationDIESEL EFFECT PROBLEM SOLVING DURING INJECTION MOULDING
RESEARCH PAPERS FACULTY OF MATERIALS SCIENCE AND TECHNOLOGY IN TRNAVA SLOVAK UNIVERSITY OF TECHNOLOGY IN BRATISLAVA 2014 Volume 22, Special Number DIESEL EFFECT PROBLEM SOLVING DURING INJECTION MOULDING
More informationGrade Selection... Coated Grades / CVD... Coated Grades / PVD... Cermet... PCBN (T-CBN)... PCD (T-DIA)... Ceramics...
Products Grade Selection... Coated / CVD... Coated / PVD... Cermet... PCBN (T-CBN)... PCD (T-DIA)... Ceramics... Uncoated Cemented Carbides... Ultra fine Grain Cemented Carbides... -2-4 -6-8 -0-2 - -4-5
More informationUnit 6: EXTRUSION. Difficult to form metals like stainless steels, nickel based alloys and high temperature metals can also be extruded.
1 Unit 6: EXTRUSION Introduction: Extrusion is a metal working process in which cross section of metal is reduced by forcing the metal through a die orifice under high pressure. It is used to produce cylindrical
More informationPRELIMINARY BROCHURE. Uddeholm Corrax
PRELIMINARY BROCHURE Uddeholm Corrax Uddeholm Corrax Uddeholm Corrax stainless moulds steel has a unique set of properties that makes it the ultimate choice in a large number of demanding applications.
More informationLapping and Polishing Basics
Lapping and Polishing Basics Applications Laboratory Report 54 Lapping and Polishing 1.0: Introduction Lapping and polishing is a process by which material is precisely removed from a workpiece (or specimen)
More informationTvrdé struženie vs. Broušení - ekonomické aspekty. Hard Turning vs. Grinding - economical aspects
Tvrdé struženie vs. Broušení - ekonomické aspekty Hard Turning vs. Grinding - economical aspects M.Sc Engg Jakub Siwiec Supervisor: dr hab. inż. Wojciech Zębala, prof. PK Abstract New production technologies
More informationSaw Tooth Design and Tipping Materials
Saw Tooth Design and Tipping Materials Bruce Lehmann, P.Eng, Ph.D. Sr. Engineer, Thin Kerf Technologies Inc. British Columbia, Canada Introduction The purposes of a saw tooth are to: 1. Remove a chip from
More informationSTAVAX SUPREME. Stainless tool steel
STAVAX SUPREME Stainless tool steel General Demands placed on plastic mould tooling are increasing. Such conditions require mould steels that possess a unique combination of toughness, corrosion resistance
More informationTIE-31: Mechanical and thermal properties of optical glass
PAGE 1/10 1 Density The density of optical glass varies from 239 for N-BK10 to 603 for SF66 In most cases glasses with higher densities also have higher refractive indices (eg SF type glasses) The density
More informationMACHINING INSTRUCTIONS FOR ENGINEERING PLASTICS
MACHINING INSTRUCTIONS FOR ENGINEERING PLASTICS in association with: ENGINEERING PLASTIC PRODUCTS Machining instructions QUADRANT Engineering Plastic Products stock shapes can be easily machined on ordinary
More informationFRAUNHOFER INSTITUTE FOR MACHINE TOOLS AND FORMING TECHNOLOGY IWU HYBRID MACHINING PROCESSES IN CUTTING TECHNOLOGY
FRAUNHOFER INSTITUTE FOR MACHINE TOOLS AND FORMING TECHNOLOGY IWU HYBRID MACHINING PROCESSES IN CUTTING TECHNOLOGY VIBRATION-SUPERIMPOSED MACHINING Hybrid Machining Processes Principle Process Variants
More informationU-Max Chamfering endmill SPMT-WL 0.17 (0.08-0.21) -WH 0.35 (0.10-0.42) R215.64. Long edge cutter 215.3 0.17 (0.10-0.20) R215.3 -AAH 0.12 (0.08-0.
General Turning PROFILING Feed recommendations Feed per tooth, fz (mm/tooth) Insert geometry Insert size Starting value (min.- max.) U-Max Chamfering endmill SPMT-WL 0.17 (0.08-0.21) -WH 0.35 (0.10-0.42)
More informationREPAIR CONCEPT SUPPORTED BY LASER REMOVAL AND INDUCTIVE HEATING
28 TH INTERNATIONAL CONGRESS OF THE AERONAUTICAL SCIENCES REPAIR CONCEPT SUPPORTED BY LASER REMOVAL AND INDUCTIVE HEATING Markus Kaden*, Rüdiger Keck* *German Aerospace Center markus.kaden@dlr.de;ruediger.keck@dlr.de
More informationAdvantages and application of PCD and CBn tools
PCD and CBN tools Advantages and application of PCD and CBn tools Powerful and economical Tools with PCD and CBN cutting edges are the ideal solution for difficult-to machine, highly abrasive materials.
More informationHow To Make A Diamond Diamond Wirehead From A Diamond
ACKNOWLEDGMENTS This work would not have been possible without the advice and support of many people. First, and foremost, I would like to thank my advisor Dr. John Patten for providing me the opportunity
More informationDetermining the Right Molding Process for Part Design
Determining the Right Molding Process for Part Design How RIM Molding Advantages Compare with Traditional Production Technologies Page 2 Introduction This White Paper details the part production processes
More informationMaterial data sheet. EOS CobaltChrome MP1. Description
EOS CobaltChrome MP1 EOS CobaltChrome MP1 is a cobalt-chrome-molybdenum-based superalloy powder which has been optimized especially for processing on EOSINT M systems. This document provides information
More informationTooling concepts Gear milling
Tooling concepts Gear milling Complete gear-cutting solutions optimized for your needs About ninety percent of all gear wheel manufacturing involves metal cutting. Your main opportunities for rationalizing
More informationAs published in PIM International
As published in PIM International www.pim-international.com 64 Powder Injection Moulding International September 2012 Rapid prototyping of highperformance ceramics opens new opportunities for the CIM industry
More informationX15TN TM. A high hardness, corrosion and fatigue resistance martensitic grade CONTINUOUS INNOVATION RESEARCH SERVICE.
TM A high hardness, corrosion and fatigue resistance martensitic grade CONTINUOUS METALLURGICAL SPECIAL STEELS INNOVATION RESEARCH SERVICE DEVELOPMENT Enhancing your performance THE INDUSTRIAL ENVIRONMENT
More informationA Fuzzy System Approach of Feed Rate Determination for CNC Milling
A Fuzzy System Approach of Determination for CNC Milling Zhibin Miao Department of Mechanical and Electrical Engineering Heilongjiang Institute of Technology Harbin, China e-mail:miaozhibin99@yahoo.com.cn
More informationRemoving chips is a method for producing plastic threads of small diameters and high batches, which cause frequent failures of thread punches.
Plastic Threads Technical University of Gabrovo Yordanka Atanasova Threads in plastic products can be produced in three ways: a) by direct moulding with thread punch or die; b) by placing a threaded metal
More informationUDDEHOLM VANADIS 30 SUPERCLEAN
UDDEHOLM VANADIS 30 SUPERCLEAN UDDEHOLMS AB No part of this publication may be reproduced or transmitted for commercial purposes without permission of the copyright holder. This information is based on
More informationNorth American Stainless
North American Stainless Flat Products Stainless Steel Sheet T409 INTRODUCTION NAS 409 is an 11% chromium, stabilized ferritic stainless steel. It is not as resistant to corrosion or high-temperature oxidation
More information3. Test Methods for Evaluation of ESCR of Plastics
3. Test Methods for Evaluation of ESCR of Plastics A common laboratory request for ESC-prone polymers is to check ESCR performance for quality control, competitive product evaluations, and research and
More informationRapid Prototyping. Training Objective
Training Objective After watching the program and reviewing this printed material, the viewer will understand the principles and practical applications of Rapid Prototyping. Basic concepts are explained
More informationDESIGN OF ADAPTIVE MULTI TOOL ARBOR ATTACHMENT
INTERNATIONAL JOURNAL OF MECHANICAL ENGINEERING AND TECHNOLOGY (IJMET) International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print), ISSN 0976 6340 (Print) ISSN 0976 6359
More information3D PRINTING OF CONTINUOUS FIBER REINFORCED PLASTIC
3D PRINTING OF CONTINUOUS FIBER REINFORCED PLASTIC Masaki NAMIKI 1, Masahito UEDA 1, Akira TODOROKI 2 Yoshiyasu HIRANO 3, Ryosuke MATSUZAKI 4 1 Nihon University, 1-8-14 Kanda-surugadai, Chiyoda, Tokyo,
More informationInvestigating Methods of Prototyping with ABS
Investigating Methods of Prototyping with ABS Ben Chapman, Shivam Desai, Mark Muraoka, Teodora Vidolova 1 Abstract In this comparative study of the mechanical properties of plastic parts produced by three
More informationThermoplastic composites
Thermoplastic composites Definition By definition, a thermoplastic is a material based on polymer (macromolecular compound) which can be shaped, in a liquid (viscous) state at a temperature either higher
More informationLecture slides on rolling By: Dr H N Dhakal Lecturer in Mechanical and Marine Engineering, School of Engineering, University of Plymouth
Lecture slides on rolling By: Dr H N Dhakal Lecturer in Mechanical and Marine Engineering, School of Engineering, University of Plymouth Bulk deformation forming (rolling) Rolling is the process of reducing
More informationPRODUCT DATA SHEET PRODUCT DESCRIPTION. Compressive Strength (0 ) ETW (1) ASTM D6641 176 ksi 1210 MPa
PRODUCT TYPE Polyetheretherketone (PEEK) Thermoplastic Resin System SERVICE TEMPERATURE Approximately 250 F (121 C) FEATURES Ambient temperature storage Flame retardant Low moisture absorption Good impact
More informationSheet metal operations - Bending and related processes
Sheet metal operations - Bending and related processes R. Chandramouli Associate Dean-Research SASTRA University, Thanjavur-613 401 Table of Contents 1.Quiz-Key... Error! Bookmark not defined. 1.Bending
More informationPIEZOELECTRIC FILMS TECHNICAL INFORMATION
PIEZOELECTRIC FILMS TECHNICAL INFORMATION 1 Table of Contents 1. PIEZOELECTRIC AND PYROELECTRIC EFFECTS 3 2. PIEZOELECTRIC FILMS 3 3. CHARACTERISTICS PROPERTIES OF PIEZOELECTRIC FILMS 3 4. PROPERTIES OF
More informationKNOCK OUT NAK80 INTRODUCING PLASTIC MOLDS RUBBER MOLDS JIGS & FIXTURES PRESS DIES. 40 HRC Pre-Hardened High Performance High Precision Mold Steel
INTRODUCING NAK80 40 HRC Pre-Hardened High Performance High Precision Mold Steel KNOCK OUT THE COMPETITION PLASTIC MOLDS RUBBER MOLDS JIGS & FIXTURES PRESS DIES Features: Machines up to 20 percent faster
More informationDFX - DFM for Flexible PCBs Jeremy Rygate
DFX - DFM for Flexible PCBs Jeremy Rygate 1 Jeremy Rygate 30 years experience with Front End in the Electronics industry and PCB manufacturing. Experience in advanced PCBs, particularly Flex, Flex-rigid
More informationPLASTIC/METAL HYBRID TECHNOLOGY. Innovative Design Solutions for Structural Performance with Weight and Cost Reduction
PLASTIC/METAL HYBRID TECHNOLOGY Innovative Design Solutions for Structural Performance with Weight and Cost Reduction LANXESS Corporation Unites Plastic and Metal to Help Manufacturers Create Products
More informationMACHINING OPERATIONS AND MACHINE TOOLS
MACHINING OPERATIONS AND MACHINE TOOLS 1. Turning and Related Operations 2. Drilling and Related Operations 3. Milling 4. Machining & Turning Centers 5. Other Machining Operations 6. Shape, Tolerance and
More informationMaterial data sheet. EOS StainlessSteel GP1 for EOSINT M 270. Description, application
EOS StainlessSteel GP1 for EOSINT M 270 A number of different materials are available for use with EOSINT M systems, offering a broad range of e-manufacturing applications. EOS StainlessSteel GP1 is a
More informationROHACELL Triple F. Complex shaped PMI Foam Cores for highly efficient FRP Composite
Complex shaped PMI Foam Cores for highly efficient FRP Composite ROHACELL Triple F Sandwich Fabrication for low to - A Novel Particle Foam high volume applications SAMPE tesdr. Kay Brazil Conference 2015
More informationOptimization of Machining Parameters to Minimize Tool Deflection in the End Milling Operation Using Genetic Algorithm
World Applied Sciences Journal 6 (1): 64-69, 2009 ISSN 1818-4952 IDOSI Publications, 2009 Optimization of Machining Parameters to Minimize Tool Deflection in the End Milling Operation Using Genetic Algorithm
More informationNaue GmbH&Co.KG. Quality Control and. Quality Assurance. Manual. For Geomembranes
Naue GmbH&Co.KG Quality Control and Quality Assurance Manual For Geomembranes July 2004 V.O TABLE OF CONTENTS 1. Introduction 2. Quality Assurance and Control 2.1 General 2.2 Quality management acc. to
More informationWelding of Plastics. Amit Mukund Joshi. (B.E Mechanical, A.M.I.Prod.E)
Welding of Plastics Amit Mukund Joshi (B.E Mechanical, A.M.I.Prod.E) Introduction Mechanical fasteners, adhesives, and welding processes can all be employed to form joints between engineering plastics.
More informationNew cutting tools from Sandvik Coromant
Supplement to Main Catalogue 2006 New cutting tools from Sandvik Coromant TURNING - MILLING - DRILLING - ORING - TOOLHOLDING CoroPak 2006.1 790 new products introduced! No compromise! With the new generation
More informationComputer-Aided Numerical Control (CNC) Programming and Operation; Lathe Introduction, Advanced Mills
1 of 6 9/9/2014 3:59 PM I. Catalog Information Credit- Degree applicable Effective Quarter: Fall 2014 MCNC 75B Computer-Aided Numerical Control (CNC) Programming and Operation; Lathe Introduction, Advanced
More informationRight Angle Grinder USA MADE FLAP DISCS
USA MADE FLAP DISC Right Angle Grinder CGW Offers the Most Extensive Line of Flap Discs in the Marketplace CGW flap discs blend and finish in one operation which replaces the traditional twostep grinding
More informationBending, Forming and Flexing Printed Circuits
Bending, Forming and Flexing Printed Circuits John Coonrod Rogers Corporation Introduction: In the printed circuit board industry there are generally two main types of circuit boards; there are rigid printed
More informationIntroduction. ε 1 θ=55 ε 2. Localized necking Because ν=0.5 in plasticity, ε 1 =-2ε 2 =-2ε 3. ε 3,ε 2
SHEET METALWORKING 1. Cutting Operation 2. Bending Operation 3. Drawing 4. Other Sheet-metal Forming 5. Dies and Presses 6. Sheet-metal Operation 7. Bending of Tube Stock 1 Introduction Cutting and forming
More informationCutting and Shearing die design Cutting die design
Manufacturing Processes 2 Dr. Alaa Hasan Ali Cutting and Shearing die design Cutting die design A stamping die is a special, one-of-a-kind precision tool that cuts and forms sheet metal into a desired
More informationAUSTENITIC STAINLESS DAMASCENE STEEL
AUSTENITIC STAINLESS DAMASCENE STEEL Damasteel s austenitic stainless Damascene Steel is a mix between types 304L and 316L stainless steels which are variations of the 18 percent chromium 8 percent nickel
More informationPRELIMINARY BROCHURE. Uddeholm Ramax HH
PRELIMINARY BROCHURE Uddeholm Ramax HH Uddeholm Ramax HH Uddeholm Ramax HH provides several benefits: The product offers uniform hardness in all dimensions combined with excellent indentation resistance.
More informationMachining nickel alloys
NiDl Nickel Development Institute Machining nickel alloys A Nickel Development Institute Reference Book, Series N o 11 008 Table of Contents Acknowledgments... i Abbreviation key... i Introduction... ii
More information3D Printed Injection Molding Tool ("PIMT") Guide. Objet Ltd.
3D Printed Injection Molding Tool ("PIMT") Guide Objet Ltd. 2 Injection molding is a high speed, automated and versatile process that can produce high precision complex three dimensional parts from a fraction
More information11 Machining, Cutting and Finishing
11 Machining, Cutting and Finishing Safety Precautions Besides the standard safety rules for mechanical operations, machining, cutting and finishing of plastic parts, unlike metals, can lead to local heating
More informationSummary of Insert Grades. Insert Lineup Turning Milling Drilling Insert Selection Table Grade Properties PCD CBN. Ceramic. Cell Fiber. Cermet.
1~15 Summary of Insert Lineup Milling Drilling Insert Selection Table Grade Properties PCD Ceramic Cell Fiber PVD Coated CVD Coated PVD Coated for PVD Coated for Milling and Drilling 2~7 2~3 4 5 5 6 7
More informationMaterial data sheet. EOS Aluminium AlSi10Mg. Description
EOS Aluminium AlSi10Mg EOS Aluminium AlSi10Mg is an aluminium alloy in fine powder form which has been specially optimised for processing on EOSINT M systems This document provides information and data
More informationTHERMAL CONDUCTIVITY AND THERMAL EXPANSION COEFFICIENT OF GFRP COMPOSITE LAMINATES WITH FILLERS
THERMAL CONDUCTIVITY AND THERMAL EXPANSION COEFFICIENT OF GFRP COMPOSITE LAMINATES WITH FILLERS K. Devendra $ and T. Rangaswamy & $ Asst. Professor, Dept. of Mech. Engineering, SKSVMACET, Laxmeshwar, KA,
More informationDuplex Stainless Steel Fabrication. Gary M. Carinci TMR Stainless Consultant for International Molybdenum Association
Duplex Stainless Steel Fabrication Gary M. Carinci TMR Stainless Consultant for International Molybdenum Association 1 Promoting molybdenum - as a material with superior properties and performance in a
More informationSheet Metal Shearing & Bending
Training Objective After watching the program and reviewing this printed material, the viewer will gain a knowledge and understanding of the principles and machine methods of shearing and bending sheetmetal
More informationChapter 5 Bridge Deck Slabs. Bridge Engineering 1
Chapter 5 Bridge Deck Slabs Bridge Engineering 1 Basic types of bridge decks In-situ reinforced concrete deck- (most common type) Pre-cast concrete deck (minimize the use of local labor) Open steel grid
More informationChapter 5 POWDER-BASED RAPID PROTOTYPING SYSTEMS
Chapter 5 POWDER-BASED RAPID PROTOTYPING SYSTEMS 5.1 3D SYSTEMS SELECTIVE LASER SINTERING (SLS) 5.1.1 Company 3D Systems Corporation was founded by Charles W. Hull and Raymond S. Freed in 1986. The founding
More informationindexable Center Drill
Our innovative tooling design upgrades productivity and competitive capability while reducing production requirements in a range of industries. The tooling system is designed to benefit users of machining
More informationUddeholm Vanadis 4 Extra SuperClean. Uddeholm Vanadis 4 Extra SuperClean
Uddeholm Vanadis 4 Extra SuperClean 1 Uddeholm Vanadis 4 Extra SuperClean CONSISTENT TOOL PERFORMANCE LONG AND RELIABLE TOOL LIFE With an increased demand for just in time deliveries (JIT) and shorter
More informationInjection molding equipment
Injection Molding Process Injection molding equipment Classification of injection molding machines 1. The injection molding machine processing ability style clamping force(kn) theoretical injection volume(cm3)
More informationMeasurement of Residual Stress in Plastics
Measurement of Residual Stress in Plastics An evaluation has been made of the effectiveness of the chemical probe and hole drilling techniques to measure the residual stresses present in thermoplastic
More informationLEADER IN CUTTING TECHNOLOGY
LEADER IN CUTTING TECHNOLOGY FOR OVER 2 YEARS REASONS WHY TRONEX IS THE BEST IN THE WORLD 1 2 SUPERIOR CUTTING PERFORMANCE Cut hundreds of thousands of times before dulling. Cut hundreds of thousands of
More informationNorth American Stainless
North American Stainless Long Products Stainless Steel Grade Sheet 2205 UNS S2205 EN 1.4462 2304 UNS S2304 EN 1.4362 INTRODUCTION Types 2205 and 2304 are duplex stainless steel grades with a microstructure,
More informationRAMAX S Prehardened stainless holder steel
T O O L S T E E L F A C T S RAMAX S Prehardened stainless holder steel Wherever tools are made Wherever tools are used This information is based on our present state of knowledge and is intended to provide
More information